Vehicle sliding door structure

ABSTRACT

A vehicle sliding door structure includes an inner door panel, an outer door panel, a reinforcing bracket and a first bulkhead. The inner door panel has a vertically oriented sash section extending along an outboard facing surface thereof adjacent to a rearward side of an outer peripheral edge thereof. The sash section has a latch mechanism supporting part proximate a mid-region of the rearward side of the outer peripheral edge. The outer door panel is fixed to the outer peripheral edge of the inner door panel. The reinforcing bracket is fixedly attached to the outboard facing surface of the inner door panel along a region of the sash section that extends from below the latch mechanism supporting part to above the latch mechanism supporting part. The first bulkhead is fixedly attached to the reinforcing bracket and extends from the reinforcing bracket toward the outer door panel.

BACKGROUND OF THE INVENTION

1. Field of the Invention

The present invention relates to a vehicle sliding door structure. Morespecifically, the present invention relates to a sliding door structurehaving a reinforced bow-resisting sliding door section.

2. Background Information

For many years, vehicles, such as passenger vans and commercial vans,have been equipped with one or more sliding doors. Such sliding doorstypically include at least two fixed tracks and corresponding slidingmechanisms that support the sliding door for sliding movement between aclosed position and an open position. The sliding door also includes atleast one of a front latching mechanism and a rear latching mechanismthat selectively retain the sliding door in the closed position.

Typically, the front and rear latching mechanisms are installed aboutmid-way up each side of the sliding door. The latching mechanisms engagestrikers (fixed bars) attached to the vehicle structure on oppositesides of the opening in the side of the vehicle.

In view of the above, it will be apparent to those skilled in the artfrom this disclosure that there exists a need for an improved slidingdoor structure. This invention addresses this need in the art as well asother needs, which will become apparent to those skilled in the art fromthis disclosure.

SUMMARY OF THE INVENTION

One object of the present invention is to provide rigidity to a rearwardand generally vertical section of a sliding door.

Another object of the invention is to locally stiffen the latchmechanism area of the sliding door for purposes of providing a slidingdoor with sufficient structural strength and rigidity.

In accordance with one embodiment of the present invention, a vehiclesliding door structure includes an inner door panel, an outer doorpanel, a reinforcing bracket and a first bulkhead. The inner door panelhas an outer peripheral edge, an outboard facing surface and avertically oriented reinforced section extending along an area of theoutboard facing surface adjacent to a rearward side of the outerperipheral edge. The reinforced section has a latch mechanism supportingpart with a latch opening located proximate a mid-region of the rearwardside of the outer peripheral edge. The outer door panel is fixed to atleast part of the outer peripheral edge of the inner door panel. Thereinforcing bracket is fixedly attached to the outboard facing surfaceof the inner door panel along a region of the reinforced section thatextends from below the latch mechanism supporting part to above thelatch mechanism supporting part. The first bulkhead is fixedly attachedto the reinforcing bracket and extends from the reinforcing brackettoward the outer door panel.

These and other objects, features, aspects and advantages of the presentinvention will become apparent to those skilled in the art from thefollowing detailed description, which, taken in conjunction with theannexed drawings, discloses a preferred embodiment of the presentinvention.

BRIEF DESCRIPTION OF THE DRAWINGS

Referring now to the attached drawings which form a part of thisoriginal disclosure:

FIG. 1 is a perspective view of a vehicle showing a sliding doorinstalled to a side portion of a vehicle structure of the vehicle inaccordance with a first embodiment of the present invention;

FIG. 2 is a side view of the vehicle showing the sliding door in aclosed position in accordance with the first embodiment of the presentinvention;

FIG. 3 is another side view of the vehicle showing the sliding door inan open position exposing an opening in the side of the vehiclestructure in accordance with the first embodiment of the presentinvention;

FIG. 4 is an exploded perspective view of the sliding door, shownremoved from the vehicle structure showing an inner door panel of thesliding door, a reinforced section of the inner door panel, areinforcing bracket, a first bulkhead, a second bulkhead, and an outerdoor panel in accordance with the first embodiment of the presentinvention;

FIG. 5 a side elevational view of the sliding door, shown removed fromthe vehicle structure with the outer door panel of the sliding doorremoved to reveal the inner door panel of the sliding door, thereinforced section of the inner door panel, the reinforcing bracketinstalled to the reinforced section of the inner door panel and thefirst and second bulkheads attached to the reinforcing bracket inaccordance with the first embodiment of the present invention;

FIG. 6 is a schematic cross-sectional view of the vehicle and thesliding door taken along the line 6-6 in FIG. 2 showing sealing contactbetween a rearward side of the inner door panel of the sliding door andthe vehicle structure in accordance with the first embodiment of thepresent invention;

FIG. 7 is a perspective view of the reinforcing bracket shown removedfrom the inner door panel of the sliding door with the first bulkheadand the second bulkhead pre-assembled to the reinforcing bracket inaccordance with the first embodiment of the present invention;

FIG. 8 is a schematic cross-sectional view of an upper region of thereinforced section of the inner door panel of the sliding door takenalong the line 8-8 in FIG. 5 showing the reinforcing bracket in solidlines and the outer door panel in phantom lines, in accordance with thefirst embodiment of the present invention;

FIG. 9 is a schematic cross-sectional view of a lower region of thereinforced section of the inner door panel of the sliding door takenalong the line 9-9 in FIG. 5 with the outer door panel in phantom lines,in accordance with the first embodiment of the present invention;

FIG. 10 is a side elevational view of the reinforcing bracket with thefirst bulkhead and the second bulkhead pre-assembled to the reinforcingbracket shown removed from the sliding door in accordance with the firstembodiment of the present invention;

FIG. 11 is a schematic cross-sectional view of an upper region of thereinforcing bracket taken along the line 11-11 in FIG. 10, showing thefirst bulkhead and the outer door panel in accordance with the firstembodiment of the present invention;

FIG. 12 is a schematic cross-sectional view of a lower region of thereinforcing bracket taken along the line 12-12 in FIG. 10, showing thesecond bulkhead and the outer door panel in accordance with the firstembodiment of the present invention;

FIG. 13 is a side elevational view of the first bulkhead shown removedfrom the reinforcing bracket in accordance with the first embodiment ofthe present invention;

FIG. 14 is a side elevational view of the second bulkhead shown removedfrom the reinforcing bracket in accordance with the first embodiment ofthe present invention;

FIG. 15 is a top view of the first bulkhead shown removed from thereinforcing bracket in accordance with the first embodiment of thepresent invention

FIG. 16 is a bottom view of the first bulkhead shown removed from thereinforcing bracket in accordance with the first embodiment of thepresent invention

FIG. 17 is a cross-sectional view of the first bulkhead taken along theline 17-17 in FIG. 15 in accordance with the first embodiment of thepresent invention;

FIG. 18 is a top view of the second bulkhead shown removed from thereinforcing bracket in accordance with the first embodiment of thepresent invention

FIG. 19 is a bottom view of the second bulkhead shown removed from thereinforcing bracket in accordance with the first embodiment of thepresent invention

FIG. 20 is a cross-sectional view of the second bulkhead taken along theline 20-20 in FIG. 19 in accordance with the first embodiment of thepresent invention;

FIG. 21 is a perspective view of the first bulkhead showing an upperside of the first bulkhead in accordance with the first embodiment ofthe present invention;

FIG. 22 is a perspective view of the second bulkhead showing an upperside of the second bulkhead in accordance with the first embodiment ofthe present invention;

FIG. 23 is a cut-away perspective view of a portion of an outboardfacing surface of the inner door panel of the sliding door lookingdownward from a rearward side of the sliding door showing thereinforcing bracket, the first bulkhead and the second bulkheadinstalled to the reinforced section of the inner door panel inaccordance with the first embodiment of the present invention;

FIG. 24 is a cut-away perspective view of a portion of the outboardfacing surface of the inner door panel of the sliding door lookingdownward from a forward side of the sliding door showing the reinforcingbracket, the first bulkhead and the second bulkhead installed to thereinforced section of the inner door panel in accordance with the firstembodiment of the present invention;

FIG. 25 is a cut-away perspective view of a portion of the outboardsurface of the inner door panel of the sliding door looking upward fromthe forward side of the sliding door showing the reinforcing bracket,the first bulkhead and the second bulkhead installed to the reinforcedsection of the inner door panel in accordance with the first embodimentof the present invention;

FIG. 26 a side elevational view of a sliding door, shown removed fromthe vehicle structure with an outer door panel of the sliding doorremoved to reveal the inner door panel of the sliding door, thereinforced section of the inner door panel, with the reinforcing bracketfixed to the reinforced section and first and second bulkheads fixed tothe reinforcing bracket in accordance with a second embodiment of thepresent invention;

FIG. 27 is an exploded perspective view of the sliding door, shownremoved from the vehicle structure showing the inner door panel of thesliding door, the reinforced section of the inner door panel, thereinforcing bracket, the first bulkhead, the second bulkhead, and theouter door panel in accordance with the second embodiment of the presentinvention;

FIG. 28 is a schematic cross sectional representation of a portion thesliding door taken along the line 28-28 in FIG. 26 showing thereinforced section of the inner door panel, the reinforcing bracket, oneof the bulkheads and the outer door panel of the sliding door inaccordance with the second embodiment of the present invention;

FIG. 29 is an exploded schematic perspective view of the section of thesliding door depicted in FIG. 28 showing from top to bottom: thereinforced section of the inner door panel; the reinforcing bracket; oneof the bulkheads; and the outer door panel of the sliding door inaccordance with the second embodiment of the present invention;

FIG. 30 is another cross section of a section the sliding door similarto FIG. 28 showing the reinforced section of the inner door panel, thereinforcing bracket, one of the bulkheads and the outer door panel ofthe sliding door in accordance with a third embodiment of the presentinvention;

FIG. 31 is an exploded perspective view of the section of the slidingdoor depicted in FIG. 30 showing from top to bottom: the reinforcedsection of the inner door panel; the reinforcing bracket; one of thebulkheads; and the outer door panel of the sliding door in accordancewith the third embodiment of the present invention;

FIG. 32 is another cross section of a section the sliding door similarto FIG. 28 showing the reinforced section of the inner door panel, thereinforcing bracket, one of the bulkheads and the outer door panel ofthe sliding door in accordance with a fourth embodiment of the presentinvention;

FIG. 33 is an exploded perspective view of the section of the slidingdoor depicted in FIG. 32 showing from top to bottom: the reinforcedsection of the inner door panel; the reinforcing bracket; first andsecond bulkheads; and the outer door panel of the sliding door inaccordance with the fourth embodiment of the present invention;

FIG. 34 is an exploded perspective view of the section of the slidingdoor showing from top to bottom: the reinforced section of the innerdoor panel; the reinforcing bracket; first and second bulkheads; and theouter door panel of the sliding door in accordance with a fifthembodiment of the present invention;

FIG. 35 is another cross section of a section the sliding door similarto FIG. 27 showing the reinforced section of the inner door panel, thereinforcing bracket, a first bulkhead and the outer door panel of thesliding door in accordance with a sixth embodiment of the presentinvention;

FIG. 36 is an exploded perspective view of the section of the slidingdoor depicted in FIG. 35 showing from top to bottom: the reinforcedsection of the inner door panel; the reinforcing bracket; first andsecond bulkheads; and the outer door panel of the sliding door inaccordance with the sixth embodiment of the present invention;

FIG. 37 is an exploded perspective view of a sliding door, shown removedfrom the vehicle structure showing an inner door panel of the slidingdoor, a reinforced section of the inner door panel, a first bulkhead, asecond bulkhead, and an outer door panel in accordance with a seventhembodiment of the present invention; and

FIG. 38 is a cross-section of the inner door panel of the sliding door,showing the reinforced section of the inner door panel with a thicknessthat is greater than the thickness of other sections of the inner doorpanel of the sliding door in accordance with the seventh embodiment ofthe present invention.

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

Selected embodiments of the present invention will now be explained withreference to the drawings. It will be apparent to those skilled in theart from this disclosure that the following descriptions of theembodiments of the present invention are provided for illustration onlyand not for the purpose of limiting the invention as defined by theappended claims and their equivalents.

Referring initially to FIG. 1, a vehicle 10 with a vehicle sliding doorstructure 12 that includes a sliding door 14 is illustrated inaccordance with a first embodiment of the present invention. The vehiclesliding door structure 12 and the sliding door 14 are provided with aunique structure that is described in greater detail below.

First a brief description of portions of the vehicle 10 is provided withspecific reference to FIGS. 1, 2 and 3. The vehicle 10 has a vehiclestructure that includes, among other components, a side body panel 20, aB-pillar 22, a C-pillar 24, a lower support portion 26 and a roof rail28. The B-pillar 22, the C-pillar 24, the lower support portion 26 andthe roof rail 28 along with the sliding door 14 at least partiallydefine the vehicle sliding door structure 12.

The side body panel 20 is supported by the B-pillar 22, the C-pillar 24,the lower support portion 26 and the roof rail 28 in a conventionalmanner. More specifically, the side body panel 20 is welded or otherwisefixedly attached to the B-pillar 22, the C-pillar 24, the lower supportportion 26 and the roof rail 28. Various non-depicted structuralelements of the vehicle 10 are conventional and description of theseconventional components is omitted for the sake of brevity.

The side body panel 20 includes a side track 30 (indicated in FIGS. 1and 2 only) and a door opening 32 (shown in FIG. 3 only). The side track30 is a conventional sliding door component that is fixed to the sidebody panel 20, the C-pillar 24 and various structural components (notshown) within the vehicle 10. The side track 30 is partially concealedby a body contour formed in the body side panel 20. Since the structuralcomponents supporting the side track 30 and the side track 30 areconventional structural elements, further description is omitted for thesake of brevity. The side track 30 is configured to support the slidingdoor 14 for sliding movement between a closed position depicted in FIG.2 and an open position depicted in FIG. 3.

The door opening 32 is formed in the side body panel 20 in aconventional manner. The door opening 32 is bordered by the B-pillar 22,the C-pillar 24, the lower support portion 26 and the roof rail 28. Morespecifically, the B-pillar 22 defines a front or forward side of thedoor opening 32, the C-pillar 24 defines a rear or rearward side of thedoor opening 32, the lower support portion 26 defines a lower side ofthe door opening 32 and the roof rail 28 defines an upper side of thedoor opening 22.

As best shown in FIG. 3, the B-pillar 22 includes a door striker 40 thatdefines part of a door latching mechanism (described further below). TheC-pillar 24 includes another striker 41 (shown only in FIG. 2) thatsimilarly defines part of the door latching mechanism. The lower supportportion 26 includes a lower track 42 and the roof rail 28 includes anupper track 44, as indicated in FIG. 3.

The side track 30, the lower track 42 and the upper track 44 extendgenerally in directions parallel to one another and are configured tosupport the sliding door 14 for sliding movement between the closedposition (FIG. 2) and the open position (FIG. 3). Since the side track30, the lower track 42 and the upper track 44 are conventional slidingdoor components, further description of these components is omitted forthe sake of brevity.

As best shown in FIG. 2 in phantom lines, the sliding door 14 includescomponents that enable the sliding movement of the sliding door 14.Specifically, the sliding door 14 includes a rear sliding mechanism 50,a lower sliding mechanism 52 and an upper sliding mechanism 54. The rearsliding mechanism 50 is a conventional mechanism that is configured andarranged to engage and slide along the side track 30. The lower slidingmechanism 52 is a conventional mechanism that is configured and arrangedto engage and slide along the lower track 42. The lower slidingmechanism 52 is positioned to support a lower forward portion of thesliding door 14. The upper sliding mechanism 54 is a conventionalmechanism that is configured and arranged to engage and slide along theupper track 44. The upper sliding mechanism 54 is positioned to supportan upper forward portion of the sliding door 14.

Together, the rear sliding mechanism 50, the side track 30, the lowersliding mechanism 52, the lower track 42, the upper sliding mechanism 54and the upper track 44 support the sliding door 14 to enable slidingmovement of the sliding door 14 between the closed position (FIG. 2) andthe open position (FIG. 3). Since the rear sliding mechanism 50, thelower sliding mechanism 52 and the upper sliding mechanism 54 areconventional components, further description is omitted for the sake ofbrevity.

As is also indicated in FIGS. 2 and 3, the sliding door 14 furtherincludes a rear latching mechanism 60, an optional front latchingmechanism 62 and a latch operating lever 64. The rear latching mechanism60 is configured and arranged to selectively engage the striker 41supported on the C-pillar 24. The front latching mechanism 62 isconfigured and arranged to selectively engage the striker 40 supportedon the B-pillar 22. The front latching mechanism 62 is an optionalfeature of the present invention in that many sliding doorconfigurations only require a single latching mechanism, typicallylocated in a rearward portion of the door. It should be understood fromthe drawings and the description herein that although both the rear andfront latching mechanisms 60 and 62 are shown included in the depictedembodiment, the present invention can be employed in a sliding door thatincludes only one latching mechanism. The latch operating lever 64 isoperably connected via cable, linkages or electric solenoids to the rearlatching mechanism 60 and the front latching mechanism 62 in aconventional manner. More specifically, the latch operating lever 64 canbe operated by a person to cause the rear latching mechanism 60 and thefront latching mechanism 62 to become disengaged from the striker 41 onthe C-pillar 24 and the striker 40 supported on the B-pillar 22.Although not shown, another latch operating lever can be installed to aninboard surface (not shown) of the sliding door 14 such that a passengerwithin the vehicle 10 can open and close the sliding door 14 from insidethe vehicle 10. The rear latching mechanism 60, the front latchingmechanism 62 and the latch operating lever 64 are all conventionalcomponents. Therefore further description of the rear latching mechanism60, the front latching mechanism 62 and the latch operating lever 64 isomitted for the sake of brevity.

A detailed description of the sliding door 14 is now provided withspecific reference to FIGS. 4-25. With initial reference to FIG. 4, thesliding door 14 basically includes an inner door panel 70, brackets 72,74, 76 and 78, a reinforcing bracket 80, a first bulkhead 82, a secondbulkhead 84 and an outer door panel 86.

As best shown in FIGS. 4 and 5, the inner door panel 70 includes anoutboard facing surface 88, an outer peripheral edge 90, a windowsection 92, an upper sliding mechanism support portion 94, a lowersliding mechanism support portion 96, a rear sliding mechanism supportportion 98, a front latch mechanism support portion 100, a rear latchmechanism support portion 102, a reinforced section 104 and a sashsection 105 (FIG. 5 only).

The outer peripheral edge 90 includes a front side 90 a, a lower side 90b, a rear side 90 c and an upper side 90 d. The window section 92 is anarea of the inner door panel 70 configured to receive an optional paneof glass for a window. Hence, the sliding door 14 can include a window.The sliding door 14 of the present invention can be a commercial vehiclewith a solid exterior that does not include a window. Alternatively, thesliding door 14 can be a passenger vehicle that includes a glass window.However, in the depicted embodiment, the outline of a window isindicated in the outer door panel 86, but no glass window is included inthe depicted embodiment.

The inner door panel 70 also has an upper rear corner 106 and a lowerrear corner 108. The upper rear corner 106 is located at theintersection of the rear side 90 c and the upper side 90 d of the outerperipheral edge 90. The lower rear corner 108 is located at theintersection of the rear side 90 c and the lower side 90 b of the outerperipheral edge 90.

An inboard surface (not shown) of the inner door panel 70 at the uppersliding mechanism support portion 94 is configured to receive andsupport the upper sliding mechanism 54, as indicated in phantom in FIGS.2 and 5. The lower sliding mechanism support portion 96 is configured toreceive and support the lower sliding mechanism 52, as is also indicatedin FIGS. 2 and 5. The brackets 72 and 74 are fixed to the outboardfacing surface 88 such that the bracket 72 provides reinforcement to theregion around the upper sliding mechanism support portion 94 and thebracket 74 provides reinforcement to the region around the front latchmechanism support portion 100.

The rear sliding mechanism support portion 98 (and a correspondingportion of the reinforcing bracket 80) are configured to support therear sliding mechanism 50 in a conventional manner. The rear latchmechanism support portion 102 is configured to support the rear latchingmechanism 60. Further, as shown in FIGS. 4 and 5, the rear latchmechanism support portion 102 includes a latch opening 110 and thereinforcing bracket 80 is provided with a latch opening 112 such thatthe rear latching mechanism 60 can selectively engage the striker (notshown) fixed to the C-pillar 24 in a conventional manner. With thereinforcing bracket 80 fixed to outboard facing surface 88 of the innerdoor panel 70 at the rear latch mechanism support portion 102, the latchopening 110 and the latch opening 112 are aligned with one another.

The front latch mechanism support portion 100 and the bracket 74 aresimilarly configured to support the front latching mechanism 62. Thefront latch mechanism support portion 100 of the inner door panel 70 isprovided with a latch opening 114 and the bracket 74 is similarlyprovided with a latch opening 116, as indicated in FIGS. 4 and 5. Withthe bracket 74 fixed to the front latch mechanism support portion 100by, for example welding techniques, the latch opening 114 is alignedwith the latch opening 116.

A description of the reinforced section 104 of the inner door panel 70is now provided with specific reference to FIGS. 5, 8 and 9. Thereinforced section 104 is a stiffened portion of the inner door panel70. The reinforced section 104 extends vertically from the upper side 90d of the outer peripheral edge 90 of the inner door panel 70 to thelower side 90 c of the outer peripheral edge 90 of the inner door panel70. Further, the reinforced section 104 extends along the rear side 90 cof the outer peripheral edge 90 of the inner door panel 70.

The reinforced section 104 is a vertically oriented portion of the innerdoor panel 70 extending along an area of the outboard facing surface 88adjacent to the rear side 90 c (the rearward side of the outerperipheral edge 90). The rear latch mechanism support portion 102 (alatch mechanism supporting part) and the latch opening 110 are locatedwithin the reinforced section 104. More specifically, the rear latchmechanism support portion 102 and the latch opening 110 are locatedproximate a mid-region of the rear side 90 c of the outer peripheraledge 90 within the region of the inner door panel 70 that constitutesthe reinforced section 104. It should be understood from the drawingsand description herein that the reinforced section 104 is located alongan edge of the inner door panel 70 that corresponds to the location ofthe rear latch mechanism support portion 102 and the sash section 105 ofthe sliding door 14. More specifically, the reinforced section 104 isnot necessarily located at a rearward side of the sliding door 14, butrather is positioned within the sliding door 14 to provide strength andrigidity to the reinforced portion 104 and the sash section 105. Forexample, in a vehicle where the sliding door moves in a forwarddirection to open, the reinforced section 104 can be located at aforward region of the sliding door 14. In other words, rearward andforward directions with respect to the reinforced section 104 are withreference to the vehicle 10 and are not intended to limit the locationand/or orientation of the reinforced section 104 in any way.

The reinforced section 104 extends from the rear side 90 c of the outerperipheral edge 90 of the inner door panel 70 toward the front side 90 aof the outer peripheral edge 90 of the inner door panel 70. However asindicated in FIG. 5, the reinforced section 104 preferably has a widthW₁, measured relative to a front-back overall width W₂ of the inner doorpanel 70. The width W₁ is preferably greater than 5 percent of the widthW₂ of the inner door panel 70 but preferably less than 25 percent of thewidth W₂ of the inner door panel 70. In the depicted embodiment thewidth W₁ is approximately 20 percent of the width W₂ of the inner doorpanel 70.

The reinforced section 104 includes a plurality of vertically extendingsurfaces formed along the outboard facing surface 88, as best shown inFIGS. 8 and 9. These vertically extending surfaces are contoured suchthat they change in width and depth going from the upper side 90 d tothe lower side 90 b of the inner door panel 70. For instance, in anupper cross-section shown in FIG. 8, surfaces 104 a, 104 b, 104 c, 104 dand 104 e are visibly angularly offset from one another. A lowercross-section shown in FIG. 9 shows that the surfaces 104 a, 104 b, 104c, 104 d and 104 e are still angularly offset from one another, but havediffering widths when compared to FIG. 8. Further, additional contouredsurfaces, such as surfaces 104 f and 104 g are formed in lower regionsof the reinforced section 104. It should be understood from the drawingsand description herein that the reinforced section 104 includes othercontoured surfaces in addition to the surfaces 104 a, 104 b, 104 c, 104d, 104 e, 104 f and 104 g. Further, the surfaces 104 a, 104 b, 104 c,104 d, 104 e, 104 f and 104 g are preferred ones of a plurality ofcontoured surfaces mentioned to exemplify the types of contouredsurfaces of the reinforced section 104.

It should also be understood from the drawings and the descriptionherein that the reinforced section 104 can have any of a variety ofshapes and configurations. In other words, the present invention is notlimited to the depicted shapes of contoured surfaces of the reinforcedsection 104.

As indicated in FIG. 5, the sash section 105 (indicated by a triangularshaped dashed line) is a portion of the sliding door 14 that iscantilevered from the upper sliding mechanism support portion 94 and therear sliding mechanism support portion 98. The sliding door 14 has threeregions that support the sliding door 14 to the vehicle 10.Specifically, the upper sliding mechanism support portion 94, the lowersliding mechanism support portion 96 and the rear sliding mechanismsupport portion 98 support the sliding door 14 to the vehicle 10.

As indicated in FIGS. 4 and 5, the brackets 72, 74, 76 and 78 are allrigidly attached to the inner door panel 70 in order to providestiffness or rigidity to the inner door panel 70 in the regions wherethe brackets 72, 74, 76 and 78 are installed. Specifically, the bracket72 reinforces the upper sliding mechanism support portion 94 of theinner door panel 70. The bracket 74 reinforces the front latch mechanismsupport portion of the inner door panel 70. The bracket 76 reinforces alower front portion of the inner door panel 70 adjacent to andsurrounding the lower sliding mechanism support portion 98 and the rearlatch mechanism support portion 102 of the inner door panel 70. Thebracket 78 extends between a forward portion of the bracket 76 and therear side 90 c of the outer peripheral edge 90 of the inner door panel70. The brackets 72, 74, 76 and 78 are preferably welded in position toa corresponding section of the outboard facing surface 88 of the innerdoor panel 70.

A description of the reinforcing bracket 80 is now provided withspecific reference to FIGS. 7, 8, 10, 11 and 12. The reinforcing bracket80 is preferably made of a sheet metal material that is formed toachieve the shapes and contours depicted in FIGS. 7 and 10. Thereinforcing bracket 80 has an approximate overall vertical height thatis preferably about half the overall vertical height of the inner doorpanel 70. However, it should be understood from the drawings and thedescription herein that the overall height of the reinforcing bracket 80can vary depending upon the design and configuration of the sliding door14. Consequently the reinforcing bracket 80 can have a vertical heightthat is smaller or larger than the depicted height. The reinforcingbracket 80 is preferably fixedly attached to the outboard facing surface88 of the inner door panel 70 along a region of the reinforced section104 that extends from below the rear latch mechanism support portion 102to above the rear latch mechanism support portion 102 (the latchmechanism supporting part). Additionally, the reinforcing bracket 80 canalso extend to below the rear slider mechanism support portion 98, asshown in FIG. 5. The reinforcing bracket 80 is preferably welded to theinner door panel 70 but can alternatively be attached by a plurality offastening elements.

The reinforcing bracket 80 includes a plurality of contoured surfacesections, such as the surface sections 80 a, 80 b, 80 c, 80 d, 80 e, 80f, 80 g and 80 h that are angularly offset from one another when viewedin cross-section, as indicated in FIGS. 7, 8, 11, 12 and 23-25. As bestshown in FIGS. 11 and 12, the surface sections 80 a, 80 b, 80 c, 80 dand 80 e are dimensioned for attachment to corresponding flange sections(described below) of the first bulkhead 82. Further, the surfacesections 80 a, 80 b, 80 c, 80 f, 80 g and 80 h are dimensioned forattachment to corresponding flanges (described below) of the secondbulkhead 84.

A description of the first bulkhead 82 is now provided with specificreference to FIGS. 10, 11, 13, 15-17, 21 and 23-25. The first bulkhead82 is a bracing member preferably made of metal that is attached to thereinforcing bracket 80 and extends from the reinforcing bracket 80toward the outer door panel 86. The first bulkhead 82 is attached to thereinforcing bracket 80 above the rear latch mechanism support portion102.

The first bulkhead 82 includes a central flat part 120 and a flange 122that encircles the central flat part 120. The first bulkhead 82 has aninverted bowl shape when viewed in cross-section, as shown in FIG. 17.Consequently as indicated in FIGS. 7, 11, 15, 23 and 24, the firstbulkhead 82 has an overall convex shape when viewed from above. Asindicated in FIGS. 16 and 25, the first bulkhead 82 an overall concaveshape when viewed from below.

As indicated in FIGS. 15-17, the central flat part 120 includes acontoured section 120 a that is convex on an upper side 82 a of thefirst bulkhead 82 and is concaved on a lower side 82 b of the firstbulkhead 82. The contoured section 120 a has a curved shape and isincluded to provide rigidity to the central flat part 120 of the firstbulkhead 82.

The flange 122 includes a plurality of flange sections 122 a, 122 b, 122c, 122 d, 122 e, 122 f and 122 g. The flange sections 122 a, 122 b, 122c and 122 d are preferably fixed to corresponding surfaces of thereinforcing bracket 80. Specifically, as best shown in FIG. 11, theflange section 122 a is fixed to the surface section 80 a of thereinforcing bracket 80; the flange section 122 b is fixed to the surfacesection 80 b of the reinforcing bracket 80; the flange section 122 c isfixed to the surface section 80 c of the reinforcing bracket 80; and theflange section 122 d is fixed to the surface section 80 d of thereinforcing bracket 80. As indicated in FIG. 10, the flange section 122g extends under a curved portion of the surface section 80 e of the ofthe reinforcing bracket 80 and is fixed thereto. The flange sections 122a, 122 b, 122 c, 122 d and 122 g are preferably welded to thereinforcing bracket 80 using conventional welding techniques or areotherwise rigidly fixed to the reinforcing bracket 80. The curvedportion of the surface section 80 e corresponds to the shape of aperimeter 144 of the window section 92. With the flange section 122 gbeing welded or otherwise fixed to the surface section 80 e and theflange section 122 a being welded or otherwise fixed to the surfacesection 80 a of the reinforcing bracket 80, the first bulkhead 82effectively spans between the rear side 90 c of the inner door panel 70and the window section 92.

As indicated in FIG. 11, the flange sections 122 e and 122 f of thefirst bulkhead 82 are fixed to the outer door panel 86. The flangesections 122 e and 122 f are preferably connected to an inner surface 86a of the outer door panel 86 by a mastic or adhesive, but canalternatively be welded to the outer door panel 86.

As indicated in FIG. 5, the central flat part 120 of the first bulkhead84 extends in a first direction D₁ and the upper side 90 d of the outerperipheral edge 90 extends in a second direction D₂. The first andsecond directions D₁ and D₂ are angularly offset from one another by anacute angle α₁, as indicated in FIG. 5. The actual angular orientationof the first bulkhead 84 can be altered, depending upon the overallsliding door configuration and dimensions. In the depicted embodiment,the angle α₁ is an acute angle and is advantageous in that the firstbulkhead 84 can span between the rear side 90 c and an adjacentperimeter 144 of the window section 92, as described in greater detailbelow. It should be understood that the angle α₁ can be any angle lessthat 90 degrees, but is preferably less than 45 degrees, and still morepreferably less than 25 degrees. Further, as shown in alternateembodiments described below, the angle α₁ can be 0 degrees such that thefirst and second directions D₁ and D₂ are essentially parallel to oneanother. A description of the second bulkhead 84 is now provided withspecific reference to FIGS. 10, 12, 14 and 18-22. The second bulkhead 84is a bracing member preferably made of metal that is attached to thereinforcing bracket 80 and extends from the reinforcing bracket 80toward the outer door panel 86, as indicated in FIG. 12. The secondbulkhead 84 is attached to the reinforcing bracket 80 below the rearlatch mechanism support portion 102.

The second bulkhead 84 includes a central flat part 130 and a flange 132that encircles the central flat part 130. The second bulkhead 84 has abowl shape when viewed in cross-section, as shown in FIG. 20.Consequently as indicated in FIGS. 7, 12, 18, 22, 23 and 24, the secondbulkhead 84 has an overall concave shape when viewed from above. Asindicated in FIGS. 19 and 25, the second bulkhead 84 an overall convexshape when viewed from below.

As indicated in FIGS. 18, 20 and 22, the central flat part 130 includesa contoured section 130 a that is convex on an upper side 84 a of thesecond bulkhead 84 and is concaved on a lower side 84 b of the secondbulkhead 84. The contoured section 130 a has a curved shape and isincluded to provide rigidity to the central flat part 130 of the secondbulkhead 84.

The flange 132 includes a plurality of flange sections 132 a, 132 b, 132c, 132 d, 132 e and 132 f. The flange sections 132 a, 132 b, 132 c and132 d are preferably fixed to corresponding surfaces of the reinforcingbracket 80, as depicted in FIG. 12. Specifically, the flange section 132a is fixed to the surface section 80 a of the reinforcing bracket 80;the flange section 132 b is fixed to the surface section 80 b of thereinforcing bracket 80; the flange section 132 c is fixed to the surfacesection 80 g of the reinforcing bracket 80; the flange section 132 d isfixed to the surface section 80 c of the reinforcing bracket 80; and theflange section 132 e is fixed to the surface section 80 f of thereinforcing bracket 80. The flange sections 132 a, 132 b, 132 c and 132d are preferably welded to the reinforcing bracket 80 using conventionalwelding techniques or otherwise rigidly fixed to the reinforcing bracket80.

As also indicated in FIG. 12, the flange section 132 f of the secondbulkhead 84 can optionally be fixed to the outer door panel 86. Theflange section 132 f can optionally be connected to an inner surface 86a of the outer door panel 86 by a mastic or adhesive, and canalternatively be welded to the outer door panel 86.

As shown in FIG. 5, the central flat part 130 of the second bulkhead 84extends in a third direction D₃. The first direction D₁ of the firstbulkhead 82 and the third direction D₃ of the second bulkhead 84 areangularly offset from one another by an acute angle α₂, as indicated inFIG. 5. As is also indicated in FIG. 5, third direction D₃ of thecentral flat part 130 of the second bulkhead 84 and the second directionD₂ of the upper side 90 d of the outer peripheral edge 90 are alsoangularly offset from one another by an acute angle. As mentioned abovewith respect to the first bulkhead 82, the angle α₂ depicted in FIG. 5is a preferred embodiment of the present invention. However, the angleα₂ can be altered such that the first bulkhead 82 and second bulkhead 84are oriented in directions that are parallel to one another, as shown inalternate embodiments described below. Further, the angle α₂ can be 0degrees but is preferably less than 90 degrees. Still more preferably,the angle α₂ is less than 30 degrees.

The first bulkhead 82, the second bulkhead 84 and the reinforcingbracket 80 can be pre-assembled as a single unit prior to assembly ofthe sliding door 14. Hence, the first bulkhead 82 and the secondbulkhead 84 and the reinforcing bracket 80 together define a singlesub-assembly or sub-unit structure of the sliding door 14.

A description of the outer door panel 86 is now provided with specificreference to FIGS. 1, 2, 4, 8, 9, 11 and 12. The outer door panel 86 hasan outer appearance (FIGS. 1, 2 and 4) that conforms to the overallshape of the vehicle 10. The outer door panel 86 includes an outerperipheral edge 140 that is welded or otherwise fixed to the outerperipheral edge 90 of the inner door panel 70 in a conventional manner.More specifically, the outer peripheral edge 140 of the outer door panel86 is fixed to the outer peripheral edge 90 of the inner door panel 70.

The outer door panel 86 also includes the window section 92 (FIGS. 1-4)that can be a solid metallic area, unitarily formed with the rest of theinner door panel 70, or alternatively can be cut out in order to receivewindow glass (not shown). The outer door panel 86 can also include acontoured area 146, as indicated in FIGS. 1-4, 6 and 11. The contouredarea 146 is preferably aligned with the side track 30 in order toprovide the side body panel 20 and the outer door panel 86 with aconsistent appearance with the sliding door 14 in the closed position.

As shown in FIGS. 23, 24 and 25, the first bulkhead 82 and the secondbulkhead 84 are fixed to the reinforcing bracket 80 but are notnecessarily parallel to one another. Further, the reinforcing bracket 80is further welded to the reinforced section 104 of the inner door panel70. The first bulkhead 82 and the second bulkhead 84 provide thereinforcing bracket 80 and the reinforced section 104 of the slidingdoor 14 with a rigidity that is beneficial to the entire vertical lengthof the reinforced section 104 of the inner door panel 70 and hence tothe entire sliding door 14. Specifically, the first and second bulkheads82 and 84 essentially create hat sections or boxed in sections above andbelow the rear latch mechanism support portion 102 of the inner doorpanel 70 of the sliding door 14. Hence the region around the rear latchmechanism support portion 102 of the inner door panel 70 is reinforcedproviding strength and rigidity. The sliding door 14 is more reliablyretained in the closed position with the first and second bulkheads 82and 84 installed to the reinforcing bracket 80. Further, the strengthand rigidity of the reinforced section 104 extends to the sash section105. In other words, the sash section 105 of the sliding door 14 isprovided with rigidity and strength as a result of inclusion of thefirst and second bulkheads 82 and 84 on the reinforcing bracket 80.

As indicated in FIGS. 2 and 3, the sliding door 14 is supported on thevehicle 10 by three sliding mechanisms. Specifically, the sliding door14 is supported by the lower sliding mechanism 52, the upper slidingmechanism 54 and the rear sliding mechanism 50. More specifically, thelower sliding mechanism 52 supports a lower front of area of the slidingdoor 14, the upper sliding mechanism 54 supports a front upper area ofthe sliding door 14 and the rear sliding mechanism 50 supports a centralrear area of the sliding door 14. Therefore, the upper rear corner 106and the lower rear corner 108 are basically cantilevered from the rearsliding mechanism 50.

As shown in FIG. 6, the sliding door 14 can be designed to include aslight curvature, when viewed in cross-section. The vehicle 10 also hasa corresponding curvature, as is indicated in the overall shape of theC-pillar 24. A seal S can preferably be installed along one of thefollowing: 1) continuously all the way around and adjacent to the outerperipheral edge 90 of the inner door panel 70 of the sliding door 14; or2) along the B-pillar 22, the C-pillar 24, the roof rail 28, and to thelower support portion 26 (adjacent to the door opening 32), as indicatedin FIG. 6. Regardless of the installation location of the seal S, theseal S is dimensioned and configured to provide a water tight sealbetween the outer peripheral edge 90 of the inner door panel 70 of thesliding door 14 and the B-pillar 22, the C-pillar 24, the roof rail 28and the lower support portion 26 of the vehicle 10.

The construction of the reinforced section 104, with the reinforcingbracket 80, the first bulkhead 82 and the second bulkhead 84 is suchthat the sash section 105 of the sliding door 14 remains rigid andretains its original shape relative to the remainder of the sliding door14. Consequently, the seal between the rear side 90 c of the outerperipheral edge 90 of the inner door panel 70 of the sliding door 14 andthe C-pillar 24 of the vehicle 10 can also be more reliable during thelife of the vehicle 10.

More specifically, the overall shape of the reinforced section 104, withthe surfaces 104 a, 104 b, 104 c, 104 d, 104 e, 104 f and 104 g, theoverall shape of the reinforcing bracket 80 with the surface sections 80a, 80 b, 80 c, 80 d, 80 e, 80 f, 80 g and 80 h, along with the firstbulkhead 82 and the second bulkhead 84, provide rear side 90 c of thesliding door 14 with a stable, rigid shape. The overall shape of thereinforced section 104, the overall shape of the reinforcing bracket 80,the first bulkhead 82 and the second bulkhead 84 provide the slidingdoor with stiffness or rigidity in the vertical direction minimizingflexing and deflection of the rear side 90 c of the sliding doorrelative to the rear sliding mechanism support portion 98 and the rearlatch mechanism support portion 102 of the inner door panel 70 of thesliding door 14. For example, as shown in FIG. 11, the surface 104 b iswelded or otherwise fixed to the reinforcing bracket 80 at the surfacesection 80 a, and the surface 104 e is welded or otherwise fixed to thereinforcing bracket 80 at the surface section 80 d. As mentioned above,the flange section 122 a is welded or otherwise fixed to the surfacesection 80 a of the reinforcing bracket 80 and the flange section 122 dis welded or otherwise fixed to the surface section 80 d of thereinforcing bracket 80. The surface 104 e at least partially defines theperimeter 144 of the window section 92 and the surface 104 b is adjacentto the rear side 90 c of the inner door panel 70. Consequently, asindicated in FIG. 11, the first bulkhead 82 bridges the distance betweenthe surface sections 80 a and 80 d, and consequently bridges thedistance between the surface 104 a and the surface 104 e of thereinforced section 104 of the inner door panel 70. In effect, the firstbulkhead 82 bridges the space between the rear side 90 c and the windowsection 92 of the inner door panel 70.

A description of a method of assembling the sliding door 14 is nowprovided. First, the inner door panel 70 is manufactured such that theinner door panel 70 is provided with the outer peripheral edge 90, theoutboard facing surface 88 and the vertically oriented reinforcedsection 104. The reinforced section 104 can have any of a variety ofshapes and is not limited to the contoured surfaces depicted in thedrawings. The reinforced section 104 can have more or fewer contouredsurfaces in order to provide the prescribed rigidity and stiffness. Thereinforced section 104 preferably extends along an area of the outboardfacing surface 88 adjacent to the rear side 90 c of the outer peripheraledge 90. The reinforced section 104 is further provided with the rearsliding mechanism support portion 98, the rear latch mechanism supportportion 102 and the latch opening 110 located proximate a mid-region ofthe rear side 90 c.

The reinforcing bracket 80 is manufactured with an overall shape thatmates with portions of the reinforced section 104 of the inner doorpanel 70. The first bulkhead 82 is fixed on the reinforcing bracket 80.Further, the reinforcing bracket 80 is attached to the outboard facingsurface 88 of the inner door panel 70 along the reinforced section 104such that the reinforcing bracket 80 extends from a region below therear latch mechanism support portion 102 (the latch mechanism supportingpart) to a region above the rear latch mechanism support portion 102.Additionally, the reinforcing bracket 80 can extend from a region belowthe rear sliding mechanism support portion 98 to the region above therear latch mechanism support portion 102, as shown in FIG. 5.

The outer door panel 86 is attached to the outer peripheral edge 90 ofthe inner door panel 70 such that the first bulkhead 82 extends from thereinforcing bracket 80 and the inner door panel 70 toward an inboardsurface of the outer door panel 86.

The attachment of the first bulkhead 82 to the reinforcing bracket 80 isperformed such that the first bulkhead 82 is located above the rearlatch mechanism support portion 102.

The attachment of the first bulkhead 82 to the reinforcing bracket 80 isperformed such that the central flat part 120 of the first bulkhead 82extends in the first direction D₁ and the upper side 90 d of the innerdoor panel 70 extends in the second direction D₂ with the first andsecond directions D₁ and D₂ being angularly offset from one another bythe acute angle α₁.

The present invention includes a configuration where only the secondbulkhead 84 is not employed. The second bulkhead 84 is therefore anoptional component of the sliding door 14. When the second bulkhead 84is employed, the second bulkhead 84 is attached to the reinforcingbracket 80 below the rear latch mechanism support portion 102.

Preferably, the attaching of the first bulkhead 82 to the reinforcingbracket 80 and the attaching of the second bulkhead 84 to thereinforcing bracket 80 are performed such that the central flat part 130of the second bulkhead 84 extends in the third direction D₃ with thefirst and third directions D₁ and D₃ being angularly offset from oneanother by the acute angle acute angle α₂.

Preferably, the attaching of the first bulkhead 82 is performed suchthat the flange sections 122 a, 122 b, 122 c, 122 d and 122 g (aplurality of flange parts) are fixedly attached to the reinforcingbracket 80 with the central flat part 120 of the first bulkhead 82extending from the flange sections 122 a, 122 b, 122 c, 122 d and 122 g.

Preferably, the attaching of the second bulkhead 84 is performed suchthat the flange sections 132 a, 132 b, 132 c, 132 d and 132 e (aplurality of flange parts) are fixedly attached to the reinforcingbracket 80 with the central flat part 130 of the second bulkhead 84extending from the flange sections 132 a, 132 b, 132 c, 132 d and 132 e.

Preferably, the attaching of the first bulkhead 82 includes attachingthe flange sections 122 e and 122 f (flange parts of the first bulkhead82) to the outer door panel 86. Preferably, the attaching of the secondbulkhead 84 includes attaching the flange section 132 f (a flange partof the second bulkhead 84) to the outer door panel 86.

Preferably, the providing the inner door panel 70 with the verticallyextending reinforced section 104 is performed such that the surfaces 104a, 104 b, 104 c, 104 d, 104 e, 104 f and 104 g (a plurality of contouredsurface sections) are formed on the outboard facing surface 88 of theinner door panel 70 such that the surfaces 104 a, 104 b, 104 c, 104 d,104 e, 104 f and 104 g are angularly offset from one another when viewedin cross-section.

Further, the providing of the reinforcing bracket 80 is performed suchthat the reinforcing bracket 80 is formed with the surface sections 80a, 80 b, 80 c, 80 d, 80 e, 80 f, 80 g and 80 h (a plurality of contouredsurface sections) that are angularly offset from one another when viewedin cross-section and are dimensioned for attachment to correspondingflange sections 122 a, 122 b, 122 c, 122 d, 122 e, 122 f and 122 g ofthe first bulkhead 82 and/or to corresponding flange sections 132 a, 132b, 132 c and 132 d of the flange 132 of the second bulkhead 84.

Preferably, the vehicle sliding door structure 12 is provided with thedoor opening 32 and the inner door panel 70 is dimensioned and supportedfor movement between the closed position (FIG. 2) covering the dooropening 32 and the open position exposing the door opening 32.

Preferably, the providing of the sliding door support structure 12 isperformed such that the sliding door support structure 12 includes theupper sliding mechanism 54 and the lower sliding mechanism 52. The uppersliding mechanism 54 is configured to support the upper section of theinner door panel 70 and the lower sliding mechanism 52 is configured tosupport a lower section of the inner door panel 70.

Preferably, the providing of the sliding door support structure 12 isperformed such that the sliding door support structure 12 includes therearward sliding mechanism 50 that is configured to support themid-region of the rearward side of the inner door panel 70.

Preferably, the inner door panel 70 of the sliding door 14 is providedwith the outer peripheral edge 90 and the vertically extendingreinforced section 104. The reinforced section 104 is formed along therear side 90 c (a rearward side) of the outer peripheral edge 90. Thereinforced section 104 is further provided with the rear latch mechanismsupport portion 102 with the latch opening 110 located proximate amid-region of the rear side 90 c.

Preferably, the outer door panel 86 is fixed to at least part of theouter peripheral edge 90 of the inner door panel 70 and the firstbulkhead 82 is connected to the reinforced section 104 of the inner doorpanel 70. Further, areas adjacent to the latch opening 112 of thereinforcing bracket 80 are fixed to the rear latch mechanism supportportion 102 of the inner door panel 70. The rear latch mechanism 60 (thefirst latch mechanism part) being fixed to either the inner door panel70 or the reinforcing bracket 80, is therefore positioned and configuredto engage the striker 41 (the second latch mechanism part) on theC-pillar 24 to selectively restrain the sliding door 14 against movementwith the sliding door 14 in the closed position.

Second Embodiment

Referring now to FIGS. 26-29 a sliding door 214 in accordance with asecond embodiment will now be explained. In view of the similaritybetween the first and second embodiments, the parts of the secondembodiment that are identical to the parts of the first embodiment willbe given the same reference numerals as the parts of the firstembodiment. Moreover, the descriptions of the parts of the secondembodiment that are identical to the parts of the first embodiment maybe omitted for the sake of brevity.

The sliding door 214 of the second embodiment of the present inventionincludes many of the features of the first embodiment, such as the innerdoor panel 70, the brackets 72, 74, 76, and 78 and the outer door panel86. However, in the second embodiment, the reinforcing bracket 80 isreplaced with a modified reinforcing bracket 280, the first bulkhead 82of the first embodiment is replaced with a first bulkhead 282 and thesecond bulkhead 84 of the first embodiment is replaced with a secondbulkhead 284.

In the second embodiment, the first bulkhead 282 and the second bulkhead284 are flat bracing members preferably made of metal that extend indirections approximately parallel to one another, as shown in FIGS. 26and 27.

In FIGS. 28 and 29, only the second bulkhead 284 is depicted. However,the first bulkhead 282 and the second bulkhead 284 are identical.Therefore, description of one applies to both.

FIGS. 28 and 29 show a reinforced section 204 of the inner door panel70. However this reinforced section 204 is a simplified schematic viewof the reinforced section 104 of the first embodiment, showing analternate configuration of contoured surfaces forming the reinforcedsection 204 when compared with the reinforced section 104 of the firstembodiment. The reinforcing bracket 280 is also depicted in the secondembodiment with a simplified set of contoured surfaces when compared tothe reinforcing bracket 80 of the first embodiment. The reinforcedsection 204 of the inner door panel 70 is simplified in FIGS. 28 and 29(and also in FIGS. 30-35) in order to more easily understand the variousalternate embodiments of the present invention described below.Specifically, the reinforced section 204 and the reinforcing bracket 280are depicted in FIGS. 28 and 29 with a minimal number of contouredsurfaces, whereas the depiction of the reinforced section 104 and thereinforcing bracket 80 in FIGS. 1-25 includes an increased number ofcontoured surfaces. It should be understood from the description anddrawings herein that the present invention is not limited to any onespecific shape or configuration of contoured surfaces comprising thereinforced sections 104 and 204 and corresponding contoured surfaces ofthe reinforcing brackets 80 and 280. Rather, the present invention canbe employed with a variety of reinforced section shapes and contours, inaddition to the configurations and shapes depicted in the attacheddrawings.

In FIGS. 28 and 29, the second bulkhead 284 is welded to the reinforcingbracket 280 but is spaced apart from the contoured surfaces of thereinforcing bracket 280 and the contoured surfaces of the reinforcedsection 204. The second bulkhead 284 provides rigidity and stiffness tothe reinforcing bracket 80 and the reinforced section 204 of the innerdoor panel 70. The second bulkhead 284 can optionally be provided withreinforcing ribs 284 a, as shown in FIG. 29.

Third Embodiment

Referring now to FIGS. 30 and 31 a sliding door 314 in accordance with athird embodiment will now be explained. In view of the similaritybetween the first, second and third embodiments, the parts of the thirdembodiment that are identical to the parts of the first and secondembodiments will be given the same reference numerals as the parts ofthe first and second embodiments. Moreover, the descriptions of theparts of the third embodiment that are identical to the parts of thefirst and second embodiments may be omitted for the sake of brevity.

The sliding door 314 of the third embodiment of the present inventionincludes many of the features of the first embodiment, such as the innerdoor panel 70 and the outer door panel 86, and the reinforcing bracket280 of the second embodiment. However, in the third embodiment, thesecond bulkhead 84 of the first embodiment is replaced with a secondbulkhead 384 and the first bulkhead 82 of the first embodiment isreplaced with a first bulkhead that is identical to the second bulkhead384.

In the third embodiment, the second bulkhead 384 (and first bulkhead382) is a contoured bracing member preferably made of metal that atleast partially conforms to the contoured shape of the reinforcedsection 204 of the inner door panel 70 and the contoured surfaces of thereinforcing bracket 280.

In FIGS. 30 and 31, only the second bulkhead 384 is depicted. However,the first bulkhead 382 and the second bulkhead 384 are identical.Therefore, description of one applies to both.

In FIGS. 30 and 31, the second bulkhead 384 is welded to the reinforcingbracket 280 and follows the contoured surfaces of the reinforcingbracket 280 and the reinforced section 204 and is further welded to atleast one of the contoured surfaces of the reinforced section 204, asindicated in FIG. 30. The second bulkhead 384 provides rigidity andstiffness to the reinforcing bracket 80 and the reinforced section 204of the inner door panel 70. The second bulkhead 384 can also be providedwith reinforcing rib 384 a, as shown in FIG. 31.

Fourth Embodiment

Referring now to FIGS. 32 and 33 a sliding door 414 in accordance with afourth embodiment will now be explained. In view of the similaritybetween the first, second and fourth embodiments, the parts of thefourth embodiment that are identical to the parts of the first andsecond embodiments will be given the same reference numerals as theparts of the first and second embodiments. Moreover, the descriptions ofthe parts of the fourth embodiment that are identical to the parts ofthe first and second embodiments may be omitted for the sake of brevity.

The sliding door 414 of the fourth embodiment of the present inventionincludes many of the features of the first embodiment, such as the innerdoor panel 70 and the outer door panel 86, and the reinforcing bracket280 of the second embodiment. However, in the fourth embodiment, thefirst bulkhead 82 is replaced with a first bulkhead 482 and the secondbulkhead 84 of the first embodiment is replaced with a second bulkhead484.

In the fourth embodiment, the first bulkhead 482 and the second bulkhead484 are flat metallic plate-like members with encircling flanges. Thefirst bulkhead 482 and the second bulkhead 484 are arranged in parallelwith respect to one another. The flanges of the first bulkhead 482 andthe second bulkhead 484 are contoured such that the flanges at leastpartially conform to the contoured shape of the reinforced section 204of the inner door panel 70 and the contoured surfaces of the reinforcingbracket 280. The flanges of the first bulkhead 482 and the secondbulkhead 484 are welded to the reinforcing bracket 280. The firstbulkhead 482 and the second bulkhead 484 can be attached to, adjacent toor spaced apart from the outer door panel 86.

Fifth Embodiment

Referring now to FIG. 34 a sliding door 514 in accordance with a fifthembodiment will now be explained. In view of the similarity between thefirst, second and fifth embodiments, the parts of the fifth embodimentthat are identical to the parts of the first and second embodiments willbe given the same reference numerals as the parts of the first andsecond embodiments. Moreover, the descriptions of the parts of the fifthembodiment that are identical to the parts of the first and secondembodiments may be omitted for the sake of brevity.

The sliding door 514 of the fifth embodiment of the present inventionincludes many of the features of the first embodiment, such as the innerdoor panel 70 and the outer door panel 86, and the reinforcing bracket280 of the second embodiment. However, in the fifth embodiment, thefirst bulkhead is replaced with a first bulkhead 582 and the secondbulkhead 84 of the first embodiment is replaced with a second bulkhead584.

In the fifth embodiment, the first bulkhead 582 and the second bulkhead584 are contoured bracing members preferably made of metal that areparallel to one another and at least partially conform to the contouredshape of the reinforced section 204 of the inner door panel 70 and thecontoured surfaces of the reinforcing bracket 280. The first bulkhead582 and the second bulkhead 584 have the appearance of a metallic tube,cut in half lengthwise, resembling an elongated channel. The firstbulkhead 582 and the second bulkhead 584 are welded to the contouredsurfaces of the reinforcing bracket 80. The first bulkhead 582 and thesecond bulkhead 584 can be attached to, adjacent to or spaced apart fromthe outer door panel 86.

Sixth Embodiment

Referring now to FIGS. 35 and 36 a sliding door 614 in accordance with asixth embodiment will now be explained. In view of the similaritybetween the first, second and sixth embodiments, the parts of the sixthembodiment that are identical to the parts of the first and secondembodiments will be given the same reference numerals as the parts ofthe first and second embodiments. Moreover, the descriptions of theparts of the sixth embodiment that are identical to the parts of thefirst and second embodiments may be omitted for the sake of brevity.

The sliding door 614 of the sixth embodiment of the present inventionincludes many of the features of the first embodiment, such as the innerdoor panel 70 and the outer door panel 86, and the reinforcing bracket280 of the second embodiment. However, in the sixth embodiment, thefirst bulkhead 82 is replaced with a first bulkhead 682 and the secondbulkhead 84 of the first embodiment is replaced with a second bulkhead684.

In the sixth embodiment, the first bulkhead 682 and the second bulkhead684 are contoured metallic ring-like members that are parallel to oneanother and at least partially conform to the contoured shape of thereinforced section 204 of the inner door panel 70, the contouredsurfaces of the reinforcing bracket 280 and the outer door panel 86. Thefirst bulkhead 682 and the second bulkhead 684 have a ring-likeappearance with rhomboid-like shape. The first bulkhead 682 and thesecond bulkhead 684 are welded to the contoured surfaces of thereinforcing bracket 280 and attached to the outer door panel 86 by amastic, an adhesive or similar attaching method.

The actual positioning of the bulkheads varies depending upon theoverall design of the sliding door and the contours of the reinforcedsection of the door. Computer aided engineering (CAE) applied to aspecific door design provides an optimization of location. In otherwords, the specific design, size and location of the bulkheads is notlimited to the depicted embodiments above, but is determined based uponthe specific design features of a specific sliding door. The firstembodiment is one such CAE optimization. Changes to the design of thedoor may require changes in the design, shape and positioning of thebulkheads.

Seventh Embodiment

Referring now to FIGS. 37 and 38 a sliding door 714 in accordance with aseventh embodiment will now be explained. In view of the similaritybetween the first and seventh embodiments, the parts of the seventhembodiment that are identical to the parts of the first embodiment willbe given the same reference numerals as the parts of the firstembodiment. Moreover, the descriptions of the parts of the seventhembodiment that are identical to the parts of the first embodiment maybe omitted for the sake of brevity.

The sliding door 714 of the seventh embodiment of the present inventionincludes many of the features of the first embodiment, such as thebrackets 72, 74, 76, and 78, first bulkhead 82, the second bulkhead 84and the outer door panel 86. However, in the seventh embodiment, thereinforcing bracket 80 is completely eliminated. Further in the seventhembodiment, the inner door panel 70 is replaced with a modified innerdoor panel 770. The inner door panel 770 is identical to the inner doorpanel 70 of the first embodiment, except that the reinforced section 104is modified to create a reinforced section 704. In the first embodiment,the entire inner door panel 70 preferably has an overall uniformthickness (with possible minor deviations in thickness due tomanufacturing imperfection within given tolerances). However, in theseventh embodiment, the reinforced section 704 of the inner door panel70 has a thickness T₁ that is preferably at least twice the thickness T₂of the remainder of the inner door panel 770, as shown in FIG. 38.Preferably, the thickness T₂ is a conventional thickness for the innerdoor panel of a sliding door, and the thickness T₁ is approximately adoubling of that conventional thickness.

The reinforced section 704 can be provided with the thickness T₁throughout the vertical length of the reinforced section 704 (i.e., fromthe upper side 90 d to the lower side 90 b along the rear side 90 c).However, it is also possible to provide the reinforced section 704 withthe thickness T₁ only in a region extending from above the rear latchmechanism support portion 102 to an area below the rear latch mechanismsupport portion 102. In other words, the thickness T₁ can be provided ina region of the reinforced section 704 that corresponds to thedimensions of the reinforcing bracket 80. Thus, the increase inthickness of the reinforced section 704 to the thickness T₁ makes itpossible to eliminate the reinforcing bracket 80.

In the seventh embodiment, the first bulkhead 82 and the second bulkhead84 are attached (welded) to the reinforced section 770. Specifically,the first bulkhead 82 is welded directly to the inner door panel 770above the rear latch mechanism support portion 102 and the secondbulkhead 84 is welded directly to the inner door panel 770 below therear latch mechanism support portion 102. The first bulkhead 82 and thesecond bulkhead 84 are oriented and positioned in a manner identical tothe first embodiment.

The various features of the vehicle 10 and operating mechanisms(latching and sliding mechanisms) of the sliding doors 14, 214, 314,414, 514, 614 and 714 are conventional components that are well known inthe art. Since these mechanism are well known in the art, thesestructures will not be discussed or illustrated in detail herein.Rather, it will be apparent to those skilled in the art from thisdisclosure that the components can be any type of structure and/orprogramming that can be used to carry out the present invention.

General Interpretation of Terms

In understanding the scope of the present invention, the term“comprising” and its derivatives, as used herein, are intended to beopen ended terms that specify the presence of the stated features,elements, components, groups, integers, and/or steps, but do not excludethe presence of other unstated features, elements, components, groups,integers and/or steps. The foregoing also applies to words havingsimilar meanings such as the terms, “including”, “having” and theirderivatives. Also, the terms “part,” “section,” “portion,” “member” or“element” when used in the singular can have the dual meaning of asingle part or a plurality of parts. Also as used herein to describe theabove embodiment(s), the following directional terms “forward”,“rearward”, “above”, “downward”, “vertical”, “horizontal”, “below” and“transverse” as well as any other similar directional terms refer tothose directions of a vehicle equipped with the present invention.Accordingly, these terms, as utilized to describe the present inventionshould be interpreted relative to a vehicle equipped with the presentinvention.

The terms of degree such as “substantially”, “about” and “approximately”as used herein mean a reasonable amount of deviation of the modifiedterm such that the end result is not significantly changed.

While only selected embodiments have been chosen to illustrate thepresent invention, it will be apparent to those skilled in the art fromthis disclosure that various changes and modifications can be madeherein without departing from the scope of the invention as defined inthe appended claims. For example, the size, shape, location ororientation of the various components can be changed as needed and/ordesired. Components that are shown directly connected or contacting eachother can have intermediate structures disposed between them. Thefunctions of one element can be performed by two, and vice versa. Thestructures and functions of one embodiment can be adopted in anotherembodiment. It is not necessary for all advantages to be present in aparticular embodiment at the same time. Every feature which is uniquefrom the prior art, alone or in combination with other features, alsoshould be considered a separate description of further inventions by theapplicant, including the structural and/or functional concepts embodiedby such feature(s). Thus, the foregoing descriptions of the embodimentsaccording to the present invention are provided for illustration only,and not for the purpose of limiting the invention as defined by theappended claims and their equivalents.

1. A method of assembling a vehicle sliding door structure, comprising:providing an inner door panel with an outer peripheral edge, an outboardfacing surface and a vertically oriented reinforced section extendingalong an area of the outboard facing surface adjacent to a rearward sideof the outer peripheral edge, and further providing the reinforcedsection with a latch mechanism supporting part that defines a latchopening located proximate a mid-region of the rearward side of the outerperipheral edge; providing at least one bulkhead with a central flatpart and an attachment flange that extends around a peripheral edge ofthe central flat part; fixedly attaching the attachment flange of the atleast one bulkhead to the outboard facing surface of the reinforcedsection of the inner door panel such that the central flat part extendslaterally from the reinforced section toward a forward side of the outerperipheral edge; and attaching an outer door panel to the outerperipheral edge of the inner door panel such that the central flat partof the at least one bulkhead extends from the reinforced section of theinner door panel toward an inboard surface of the outer door panel. 2.The method according to claim 1, wherein the fixedly attaching of theattachment flange of the at least one bulkhead includes fixedlyattaching the attachment flange to the reinforced section above thelatch opening.
 3. The method according to claim 2, wherein the fixedlyattaching of the attachment flange of the at least one bulkhead includesorienting the at least one bulkhead such that the central flat part ofthe at least one bulkhead extends laterally angularly offset relative toan upper side of the outer peripheral edge of the inner door panel. 4.The method according to claim 1, wherein the fixedly attaching of theattachment flange of the at least one bulkhead comprises: fixedlyattaching the attachment flange of a first bulkhead to the reinforcedsection above the latch opening; and fixedly attaching an attachmentflange of a second bulkhead to the reinforced section below the latchopening.
 5. The method according to claim 4, wherein the fixedlyattaching of the attachment flange of the at least one bulkhead includesorienting the first bulkhead and the second bulkhead such that thecentral flat part of the first bulkhead extends laterally angularlyoffset from a central flat part of the second bulkhead.
 6. The methodaccording to claim 1, wherein the fixedly attaching of the attachmentflange of the at least one bulkhead includes fixedly attaching a firstsection of the attachment flange to the reinforced section and fixedlyattaching a second section of the attachment flange to an interiorfacing surface of the outer door panel.
 7. The method according to claim1, wherein the providing of the inner door panel includes providing thereinforced section with a plurality of contoured surfaces, and theproviding of the at least one bulkhead includes providing the attachmentflange with a first flange part and a second flange part, and thefixedly attaching of the attachment flange of the at least one bulkheadincludes fixedly attaching the first flange part and the second flangepart to corresponding ones of the plurality of contoured surfaces of thereinforced section.
 8. The method according to claim 7, wherein theproviding of the at least one bulkhead includes providing the attachmentflange with a third flange part, and the fixedly attaching of theattachment flange of the at least one bulkhead includes fixedlyattaching the third flange part to the inner facing surface of the outerdoor panel.
 9. The method according to claim 7, wherein the providing ofthe inner door panel includes providing the plurality of contouredsurfaces of the reinforced section with a first surface, a secondsurface angularly offset from the first surface, and a third surfaceangularly offset from the second surface such that the third surfacefaces the first surface, the providing of the at least one bulkheadfurther includes providing the attachment flange with a third flangepart, and the fixedly attaching of the attachment flange of the at leastone bulkhead includes fixedly attaching the first flange part to thefirst surface, fixedly attaching the second flange part to the secondsurface, and fixedly attaching the third flange part to the thirdsurface.
 10. The method according to claim 9, wherein the providing ofthe inner door panel includes providing the inner door panel with awindow section such that the third surface of the contoured surfaces isdefined along an area of the window section, and the fixedly attachingof the attachment flange of the at least one bulkhead includes orientingthe at least one bulkhead such that the central flat part of the atleast one bulkhead bridges a space between the first surface and thewindow section.
 11. The method according to claim 1, wherein theproviding of the inner door panel includes providing the inner doorpanel with: an upper roller support part located at a forward uppercorner of the inner door panel; a lower roller support part located at aforward lower corner of the inner door panel; a rear roller support partlocated proximate the mid-region of the rearward side of the outerperipheral edge; and a sash section defined by a first line connectingthe latch mechanism supporting part to the upper roller support part, asecond line connecting the upper roller support part to a rear uppercorner, and a third line connecting the rear upper corner to the latchmechanism support part.
 12. The method according to claim 11, whereinthe fixedly attaching of the attachment flange of the at least onebulkhead includes orienting the at least one bulkhead such that thecentral flat part of the at least one bulkhead extends laterally in adirection parallel to the first line and fixedly attaching the at leastone bulkhead to the reinforced section above the latch opening.
 13. Themethod according to claim 1, wherein the providing of the inner doorpanel includes providing the reinforced section with a reinforcingbracket that is fixedly attached to the outboard facing surface of theinner door panel along a region of the reinforced section that extendsfrom below the latch mechanism supporting part to above the latchmechanism supporting part and having a second latch opening in alignmentwith the latch opening of the latch mechanism supporting part, and thefixedly attaching of the attachment flange of the at least one bulkheadincludes fixedly attaching the attachment flange of the at least onebulkhead to the reinforcing bracket.
 14. A method of assembling avehicle sliding door structure comprising: providing an inner door panelwith an outer peripheral edge, an outboard facing surface, and avertically oriented reinforced section extending along an area of theoutboard facing surface adjacent to a rearward side of the outerperipheral edge, the reinforced section having a latch mechanismsupporting part with a first latch opening located proximate amid-region of the rearward side of the outer peripheral edge, an upperroller support part located at a forward upper corner of the inner doorpanel, a lower roller support part located at a forward lower corner ofthe inner door panel, a rear roller support part located proximate themid-region of the rearward side of the outer peripheral edge; providingat least one bulkhead with a central flat part and an attachment flangethat extends around a peripheral edge of the central flat part; fixedlyattaching the attachment flange of the at least one bulkhead to theoutboard facing surface of the reinforced section of the inner doorpanel such that the central flat part extends laterally from thereinforced section toward a forward side of the outer peripheral edge;and attaching an outer door panel to the outer peripheral edge of theinner door panel such that the central flat part of the at least onebulkhead extends from the reinforced section of the inner door paneltoward an inboard surface of the outer door panel.
 15. The methodaccording to claim 14, wherein the fixedly attaching of the attachmentflange of the at least one bulkhead includes fixedly attaching theattachment flange to the reinforced section above the latch opening. 16.The method according to claim 15, wherein the fixedly attaching of theattachment flange of the at least one bulkhead includes orienting the atleast one bulkhead such that the central flat part of the at least onebulkhead extends laterally angularly offset relative to an upper side ofthe outer peripheral edge of the inner door panel.
 17. The methodaccording to claim 14, wherein the fixedly attaching of the attachmentflange of the at least one bulkhead comprises: fixedly attaching theattachment flange of a first bulkhead to the reinforced section abovethe latch opening; and fixedly attaching an attachment flange of asecond bulkhead to the reinforced section below the latch opening. 18.The method according to claim 17, wherein the fixedly attaching of theattachment flange of the at least one bulkhead includes orienting thefirst bulkhead and the second bulkhead such that the central flat partof the first bulkhead extends laterally angularly offset from a centralflat part of the second bulkhead.
 19. The method according to claim 14,wherein the fixedly attaching of the attachment flange of the at leastone bulkhead includes fixedly attaching a first section of theattachment flange to the reinforced section and fixedly attaching asecond section of the attachment flange to an interior facing surface ofthe outer door panel.
 20. The method according to claim 14, wherein theproviding of the inner door panel includes providing the reinforcedsection with a plurality of contoured surfaces, and the providing of theat least one bulkhead includes providing the attachment flange with afirst flange part and a second flange part, and the fixedly attaching ofthe attachment flange of the at least one bulkhead includes fixedlyattaching the first flange part and the second flange part tocorresponding ones of the plurality of contoured surfaces of thereinforced section.
 21. The method according to claim 20, wherein theproviding of the at least one bulkhead includes providing the attachmentflange with a third flange part, and the fixedly attaching of theattachment flange of the at least one bulkhead includes fixedlyattaching the third flange part to the inner facing surface of the outerdoor panel.
 22. The method according to claim 20, wherein the providingof the inner door panel includes providing the plurality of contouredsurfaces of the reinforced section with a first surface, a secondsurface angularly offset from the first surface, and a third surfaceangularly offset from the second surface such that the third surfacefaces the first surface, the providing of the at least one bulkheadfurther includes providing the attachment flange with a third flangepart, and the fixedly attaching of the attachment flange of the at leastone bulkhead includes fixedly attaching the first flange part to thefirst surface, fixedly attaching the second flange part to the secondsurface, and fixedly attaching the third flange part to the thirdsurface.
 23. The method according to claim 22, wherein the providing ofthe inner door panel includes providing the inner door panel with awindow section such that the third surface of the contoured surfaces isdefined along an area of the window section, and the fixedly attachingof the attachment flange of the at least one bulkhead includes orientingthe at least one bulkhead such that the central flat part of the atleast one bulkhead bridges a space between the first surface and thewindow section.
 24. The method according to claim 14, wherein theproviding of the inner door panel includes providing the inner doorpanel with a sash section defined by a first line that extends from thelatch mechanism supporting part to the upper roller support part, asecond line that extends from the upper roller support part to a rearupper corner of the inner door panel, and a third line that extends fromthe rear upper corner of the door panel to the latch mechanism supportpart, and the fixedly attaching of the attachment flange of the at leastone bulkhead includes orienting the at least one bulkhead such that thecentral flat part of the first bulkhead extends in a direction parallelto the first line and fixedly attaching the attachment flange of the atleast one bulkhead to the reinforced section above the latch opening.25. The method according to claim 14, wherein the providing of the innerdoor panel includes providing the reinforced section with a reinforcingbracket that is fixedly attached to the outboard facing surface of theinner door panel along a region of the reinforced section that extendsfrom below the latch mechanism supporting part to above the latchmechanism supporting part and having a second latch opening in alignmentwith the latch opening of the latch mechanism supporting part, and thefixedly attaching of the attachment flange of the at least one bulkheadincludes fixedly attaching the attachment flange of the at least onebulkhead to the reinforcing bracket.